Method for Producing Three Separate and Distinct Intake Manifolds from a Single Intake Manifold Casting For Three Different Multi-Cylinder Internal Combustion Engine Applications

Abstract

A method for producing different distinct intake manifolds from a single intake manifold casting mold. It is the objective of the present invention to reduce costs and tooling for the manufacturing of different intake manifolds by using a single intake manifold casting mold. The intake manifolds created by the casting mold are then differentiated for a corresponding engine by means of modifications. The intake runners of the intake manifolds are machine cut to fit the corresponding cylinder heads of the combustion engine. The modifications to the intake modification ensure maximum air flow efficiency for greater engine performance.

1 . A method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications comprises,
 providing an intake mold being shaped for casting an intake manifold;   providing by the intake mold a plurality of intake runners for the intake manifold;   providing by the intake mold a plurality of core cavities for receiving a plurality of casting cores to form the plurality of intake runners;   providing by the intake mold a plurality of solid casting cores to shape internal passageways for the plurality of intake runners;   providing by the intake mold a chamber solid casting core to shape an internal plenum chamber for the intake manifold;   securing the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core in place with the intake mold to ensure integrity;   pouring an intake manifold material into the intake mold around the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core to form the intake manifold;   removing of intake mold; and   removing of the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core from the intake manifold.   
     
     
         2 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 1  comprises,
 the intake manifold material being a sturdy heat resistant material being selected from the group consisting of liquid nylon, polymers, and metal. 
 
     
     
         3 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 1  comprises,
 the plurality of solid casting cores being alternatively inserted in a parallel manner to one another; and 
 the plurality of solid casting cores providing the intake manifold with the plurality of intake runners for corresponding communication to individual ports of corresponding engine cylinder heads with the internal plenum chamber. 
 
     
     
         4 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 3  comprises,
 the plurality of solid casting cores and the plurality of casting cores being shaped in a logarithmic spiral shape to provide the plurality of intake runners of the intake manifold a channel leading from the engine cylinder heads to the internal plenum chamber; and 
 the plurality of solid casting cores being arranged in an alternating manner to correspond to the positioning of the engine cylinder heads. 
 
     
     
         5 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 4  comprises,
 the plurality of solid casting cores being positioned about and leading to the chamber solid casting core to circumscribe the plenum chamber of the intake manifold. 
 
     
     
         6 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 1  comprises,
 the plurality of intake runners having runner openings leading into the internal passageways; 
 machine cutting the runner openings of the intake runners to precisely match shapes and configurations of inlet ports of each specific engine cylinder head; 
 machine cutting partially of the internal passageways to optimize air flow, air velocity and pressure distribution at the runner openings of the intake manifold; 
 the plurality of solid casting cores being shaped to create the different distinct intake manifolds; and 
 the internal passageways having an inner side and an outer side. 
 
     
     
         7 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 6  comprises,
 wherein the partial machining cutting of the internal passageways cuts the inner side to provide a smooth transition from the internal passageways to the engine cylinder heads. 
 
     
     
         8 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 6  comprises,
 wherein the partial machining cutting of the internal passageways cuts the outer side to provide a smooth transition from the internal passageways to the engine cylinder heads. 
 
     
     
         9 . A method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications comprises,
 providing an intake mold being shaped for casting an intake manifold;   providing by the intake mold a plurality of intake runners for the intake manifold;   providing by the intake mold a plurality of core cavities for receiving a plurality of casting cores to form the plurality of intake runners;   providing by the intake mold a plurality of solid casting cores to shape internal passageways for the plurality of intake runners;   providing by the intake mold a chamber solid casting core to shape an internal plenum chamber for the intake manifold;   securing the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core in place with the intake mold to ensure integrity;   pouring an intake manifold material into the intake mold around the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core to form the intake manifold;   removing of intake mold;   removing of the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core from the intake manifold;   the plurality of intake runners having runner openings leading into the internal passageways;   machine cutting the runner openings of the intake runners to precisely match shapes and configurations of inlet ports of each specific engine cylinder head;   machine cutting partially of the internal passageways to optimize air flow, air velocity and pressure distribution at the runner openings of the intake manifold;   the plurality of solid casting cores being shaped to create the different distinct intake manifolds; and   the internal passageways having an inner side and an outer side.   
     
     
         10 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 9  comprises,
 the intake manifold material being a sturdy heat resistant material being selected from the group consisting of liquid nylon, polymers, and metal. 
 
     
     
         11 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 9  comprises,
 the plurality of solid casting cores being alternatively inserted in a parallel manner to one another; and 
 the plurality of solid casting cores providing the intake manifold with the plurality of intake runners for corresponding communication to individual ports of corresponding engine cylinder heads with the internal plenum chamber. 
 
     
     
         12 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 11  comprises,
 the plurality of solid casting cores and the plurality of casting cores being shaped in a logarithmic spiral shape to provide the plurality of intake runners of the intake manifold a channel leading from the engine cylinder heads to the internal plenum chamber; and 
 the plurality of solid casting cores being arranged in an alternating manner to correspond to the positioning of the engine cylinder heads. 
 
     
     
         13 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 12  comprises,
 the plurality of solid casting cores being positioned about and leading to the chamber solid casting core to circumscribe the plenum chamber of the intake manifold. 
 
     
     
         14 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 9  comprises,
 wherein the partial machining cutting of the internal passageways cuts the inner side to provide a smooth transition from the internal passageways to the engine cylinder heads. 
 
     
     
         15 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 9  comprises,
 wherein the partial machining cutting of the internal passageways cuts the outer side to provide a smooth transition from the internal passageways to the engine cylinder heads. 
 
     
     
         16 . A method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications comprises,
 providing an intake mold being shaped for casting an intake manifold;   providing by the intake mold a plurality of intake runners for the intake manifold;   providing by the intake mold a plurality of core cavities for receiving a plurality of casting cores to form the plurality of intake runners;   providing by the intake mold a plurality of solid casting cores to shape internal passageways for the plurality of intake runners;   providing by the intake mold a chamber solid casting core to shape an internal plenum chamber for the intake manifold;   securing the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core in place with the intake mold to ensure integrity;   pouring an intake manifold material into the intake mold around the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core to form the intake manifold;   removing of intake mold;   removing of the plurality of core cavities, the plurality of solid casting cores, and the chamber casting core from the intake manifold;   the plurality of intake runners having runner openings leading into the internal passageways;   machine cutting the runner openings of the intake runners to precisely match shapes and configurations of inlet ports of each specific engine cylinder head;   machine cutting partially of the internal passageways to optimize air flow, air velocity and pressure distribution at the runner openings of the intake manifold;   the plurality of solid casting cores being shaped to create the different distinct intake manifolds;   the internal passageways having an inner side and an outer side;   the plurality of solid casting cores being alternatively inserted in a parallel manner to one another;   the plurality of solid casting cores providing the intake manifold with the plurality of intake runners for corresponding communication to individual ports of corresponding engine cylinder heads with the internal plenum chamber;   the plurality of solid casting cores and the plurality of casting cores being shaped in a logarithmic spiral shape to provide the plurality of intake runners of the intake manifold a channel leading from the engine cylinder heads to the internal plenum chamber; and   the plurality of solid casting cores being arranged in an alternating manner to correspond to the positioning of the engine cylinder heads.   
     
     
         17 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 16  comprises,
 the intake manifold material being a sturdy heat resistant material being selected from the group consisting of liquid nylon, polymers, and metal. 
 
     
     
         18 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 16  comprises,
 the plurality of solid casting cores being positioned about and leading to the chamber solid casting core to circumscribe the plenum chamber of the intake manifold. 
 
     
     
         19 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 16  comprises,
 wherein the partial machining cutting of the internal passageways cuts the inner side to provide a smooth transition from the internal passageways to the engine cylinder heads. 
 
     
     
         20 . The method for producing three distinct intake manifolds from a single intake manifold casting for three different multi-cylinder internal combustion engine applications as claimed in  claim 16  comprises,
 wherein the partial machining cutting of the internal passageways cuts the outer side to provide a smooth transition from the internal passageways to the engine cylinder heads.